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WHITE DELI SUB PRODUCTION PROCESS IMPROVEMENT. SOLUTION APPROACH May 21 st 2012. BACKGROUND. PROS Wonderful Product Good Quality Best Selling Good Production. CURRENT OBSERVATION Low DoS (Missing Quality) ! Remix Type and Rate Mixing Pace Breakdown s . SUPPORTING DATA.

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White deli sub production process improvement

WHITE DELI SUB PRODUCTION PROCESS IMPROVEMENT

SOLUTION APPROACH

May 21st 2012


Background
BACKGROUND

PROS

  • Wonderful Product

  • Good Quality

  • Best Selling

  • Good Production

  • CURRENT OBSERVATION

  • Low DoS (Missing Quality) !

  • Remix Type and Rate

  • Mixing Pace

  • Breakdowns


Supporting data
SUPPORTING DATA

  • Average Mixing Pace : 14mn30sec vs11mn37sec (Divider Time)

  • AverageQ1-2012 DoS11vs14 (Required for best quality)

  • Average remix rate 4.65%

  • 20% over 10% Dough Weight

  • Average Scrap rate 0.95%

  • Average Moline Line Impact 2.00%

  • Average Scaling Time 4mn

  • Average Loading Time 1mn


Solution flow
SOLUTION FLOW

Implementing work sequence

  • Process flow plan:

    work sequence and timing

  • Standard Work Diagram:

    walking path

  • Job Aid :

    training and reference


Process flow plan
Process Flow Plan

  • Ingredients Scaling

  • Ingredient Loading

  • Auto-Delivery and Mixer Starting

  • Picking up remix

  • Mixing process

  • Unloading Mixer

  • Dividing Time

  • Idle Time




Snapshot audit
Snapshot Audit

  • Using Mixer timers as reference

  • Link key process steps to timers reading

  • Read timer to assess pace keeping

  • Get back on pace after every unplanned gap


Remix policy
Remix Policy

  • Providing new Remix buckets (max weight 53lb)

  • Put additional doubles into trash

  • No remix at Divider

  • Weight and record trash at the end of every session



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